SPECIFICATIONS AND SERVICE DATA [S200] 2-3

2. Service Data

2. Service Data
NOTE:
STD: Standard, I.D.: Inner Diameter, O.D.: Outer Diameter, OS: Oversize, US: Undersize
Belt
ten-
Protrusion of adjuster rod 5.2 — 6.2 mm (0.205 — 0.244 in)
sioner
adjuster
Spacer O.D. 17.955 — 17.975 mm (0.7069 — 0.7077 in)
Tensioner bush I.D 18.00 — 18.08 mm (0.7087 — 0.7118 in)
Belt
STD 0.025 — 0.125 mm (0.0010 — 0.0049 in)
ten- Clearance between spacer and bush
Limit 0.175 mm (0.0069 in)
sioner
STD 0.2 — 0.55 mm (0.0079 — 0.0217 in)
Side clearance of spacer
Limit 0.81 mm (0.0319 in)
Valve STD 0.020 — 0.054 mm (0.0008 — 0.0021 in)
rocker Clearance between shaft and arm
arm Limit 0.10 mm (0.0039 in)
Bend limit 0.020 mm (0.0008 in)
STD 0.030 — 0.090 mm (0.0012 — 0.0035 in)
Thrust clearance
Limit 0.11 mm (0.0043 in)
STD 38.732 — 38.832 mm (1.5249 — 1.5288 in)
Intake
Limit 38.632 mm (1.5209 in)
Cam lobe height (2200 cc)
STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Cam-
STD 39.485 — 39.585 mm (1.5545 — 1.5585 in)
shaft Intake
Limit 39.385 mm (1.5506 in)
Cam lobe height (2500 cc)
STD 39.257 — 39.357 mm (1.5455 — 1.5495 in)
Exhaust
Limit 39.157 mm (1.5416 in)
Camshaft journal O.D. 31.928 — 31.945 mm (1.2570 — 1.2577 in)
Camshaft journal hole I.D. 32.000 — 32.018 mm (1.2598— 1.2605 in)
STD 0.055 — 0.090 mm (0.0022 — 0.0035 in)
Oil clearance
Limit 0.118 mm (0.0046 in)
Surface warpage limit 0.05 mm (0.0020 in)
Cylinder
Surface grinding limit 0.3 mm (0.012 in)
head
Standard height 127.5 mm (5.02 in)
Refacing angle 90°
STD 1.0 mm (0.039 in)
Valve Intake
Limit 1.7 mm (0.067 in)
set Contacting width
STD 1.4 mm (0.055 in)
Exhaust
Limit 2.1 mm (0.083 in)
Inner diameter 6.000 — 6.012 mm (0.2362 — 0.2367 in)
Valve
Intake 20.0 — 20.5 mm (0.787 — 0.807 in)
guide Protrusion above head
Exhaust 16.5 — 17.0 mm (0.650 — 0.669 in)

3
2-3 [S200] SPECIFICATIONS AND SERVICE DATA
2. Service Data

STD 1.0 mm (0.039 in)

Intake
Limit 0.6 mm (0.024 in)
Head edge thickness
STD 1.2 mm (0.047 in)
Exhaust
Limit 0.6 mm (0.024 in)
Intake 5.950 — 5.965 mm (0.2343 — 0.2348 in)
Stem diameter
Valve Exhaust 5.945 — 5.960 mm (0.2341 — 0.2346 in)
Intake 0.035 — 0.062 mm (0.0014 — 0.0024 in)
STD
Stem oil clearance Exhaust 0.040 — 0.067 mm (0.0016 — 0.0026 in)
Limit — 0.15 mm (0.0059 in)
Intake 120.6 mm (4.75 in)
Overall length
Exhaust 121.7 mm (4.79 in)
Free length 54.30 mm (2.1378 in)
Squareness 2.5°, 2.4 mm (0.094 in)
214.8 — 246.2 N
Valve (21.9 — 25.1 kg, 48.3 — 55.3 lb)/45.0 mm (1.772
spring in)
Tension/spring height
526.6 — 581.6 N
(53.7 — 59.3 kg, 118.4 — 130.8 lb)/34.7 mm
(1.366 in)
Surface warpage limit (mating with cylinder head) 0.05 mm (0.0020 in)
Surface grinding limit 0.1 mm (0.004 in)
A 96.905 — 96.915 mm (3.8151 — 3.8155 in)
Cylinder bore (2200 cc) STD
B 96.895 — 96.905 mm (3.8148 — 3.8151 in)
A 99.505 — 99.515 mm (3.9175 — 3.9179 in)
Cylinder bore (2500 cc) STD
B 99.495 — 99.505 mm (3.9171 — 3.9175 in)
Cylinder
STD 0.015 mm (0.0006 in)
block Taper
Limit 0.050 mm (0.0020 in)
STD 0.010 mm (0.0004 in)
Out-of-roundness
Limit 0.050 mm (0.0020 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Piston clearance
Limit 0.050 mm (0.0020 in)
Enlarging (boring) limit 0.5 mm (0.020 in)
A 96.885 — 96.895 mm (3.8144 — 3.8148 in)
STD
B 96.875 — 96.885 mm (3.8140 — 3.8144 in)
0.25 mm (0.0098
Outer diameter (2200 cc) 97.125 — 97.135 mm (3.8238 — 3.8242 in)
in) OS
0.50 mm (0.0197
97.375 — 97.385 mm (3.8337 — 3.8340 in)
in) OS
Piston
A 99.485 — 99.495 mm (3.9167 — 3.9171 in)
STD
B 99.475 — 99.485 mm (3.9163 — 3.9167 in)
0.25 mm (0.0098
Outer diameter (2500 cc) 99.725 — 99.735 mm (3.9262 — 3.9266 in)
in) OS
0.50 mm (0.0197
99.975 — 99.985 mm (3.9360 — 3.9364 in)
in) OS
Standard clearance between piston pin and STD 0.004 — 0.008 mm (0.0002 — 0.0003 in)
Piston hole in piston Limit 0.020 mm (0.0008 in)
pin Piston pin must be fitted into position with thumb at
Degree of fit
20°C (68°F).

4
 SPECIFICATIONS AND SERVICE DATA [S200] 2-3
2. Service Data

STD 0.20 — 0.35 mm (0.0079 — 0.0138 in)

Top ring
Limit 1.0 mm (0.039 in)
STD 0.37 — 0.52 mm (0.0146 — 0.0205 in)
Piston ring gap Second ring
Limit 1.0 mm (0.039 in)
Piston STD 0.20 — 0.50 mm (0.0079 — 0.0197 in)
Oil ring
ring Limit 1.0 mm (0.039 in)
STD 0.040 — 0.080 mm (0.0016 — 0.0031 in)
Clearance between pis- Top ring
Limit 0.15 mm (0.0059 in)
ton ring and piston ring
groove STD 0.030 — 0.070 mm (0.0012 — 0.0028 in)
Second ring
Limit 0.15 mm (0.0059 in)
Con- Bend twist per 100 mm (3.94 in) in length Limit 0.10 mm (0.0039 in)
necting STD 0.070 — 0.330 mm (0.0028 — 0.0130 in)
Side clearance
rod Limit 0.4 mm (0.016 in)
STD 0.010 — 0.038 mm (0.0004 — 0.0015 in)
Oil clearance (2200 cc)
Limit 0.05 mm (0.0020 in)
STD 0.020 — 0.046 mm (0.0008 — 0.0018 in)
Oil clearance (2500 cc)
Limit 0.050 mm (0.0020 in)
STD 1.492 — 1.501 mm (0.0587 — 0.0591 in)
0.03 mm (0.0012
1.510 — 1.513 mm (0.0594 — 0.0596 in)
in) US
Con- Thickness at center portion (2200 cc) 0.05 mm (0.0020
necting 1.520 — 1.523 mm (0.0598 — 0.0600 in)
in) US
rod 0.25 mm (0.0098
bearing 1.620 — 1.623 mm (0.0638 — 0.0639 in)
in) US
STD 1.486 — 1.498 mm (0.0585 — 0.0590 in)
0.03 mm (0.0012
1.504 — 1.512 mm (0.0592 — 0.0595 in)
in) US
Thickness at center portion (2500 cc) 0.05 mm (0.0020
1.514 — 1.522 mm (0.0596 — 0.0599 in)
in) US
0.25 mm (0.0098
1.614 — 1.622 mm (0.0635 — 0.0639 in)
in) US
Con-
STD 0 — 0.022 mm (0 — 0.0009 in)
necting
Clearance between piston pin and bushing
rod
Limit 0.030 mm (0.0012 in)
bushing

5
2-3 [S200] SPECIFICATIONS AND SERVICE DATA
2. Service Data

Bend limit 0.035 mm (0.0014 in)

Out-of-roundness 0.030 mm (0.0012 in) or less
Crankpin and crank journal
Grinding limit 0.250 mm (0.0098 in)
STD 51.984 — 52.000 mm (2.0466 — 2.0472 in)
0.03 mm (0.0012
51.954 — 51.970 mm (2.0454 — 2.0461 in)
in) US
Crankpin outer diameter 0.05 mm (0.0020
51.934 — 51.950 mm (2.0446 — 2.0453 in)
in) US
0.25 mm (0.0098
51.734 — 51.750 mm (2.0368 — 2.0374 in)
in) US
STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012
59.962 — 59.978 mm (2.3607 — 2.3613 in)
in) US
Crank- #1, #5, #3 0.05 mm (0.0020
59.942 — 59.958 mm (2.3599 — 2.3605 in)
shaft in) US
0.25 mm (0.0098
59.742 — 59.758 mm (2.3520 — 2.3527 in)
Crank journal outer in) US
diameter STD 59.992 — 60.008 mm (2.3619 — 2.3625 in)
0.03 mm (0.0012
59.962 — 59.978 mm (2.3607 — 2.3613 in)
in) US
#2, #4 0.05 mm (0.0020
59.942 — 59.958 mm (2.3599 — 2.3605 in)
in) US
0.25 mm (0.0098
59.742 — 59.758 mm (2.3520 — 2.3527 in)
in) US
STD 0.030 — 0.115 mm (0.0012 — 0.0045 in)
Thrust clearance
Limit 0.25 mm (0.0098 in)
STD 0.010 — 0.030 mm (0.0004 — 0.0012 in)
Oil clearance
Limit 0.040 mm (0.0016 in)
STD 1.998 — 2.011 mm (0.0787 — 0.0792 in)
0.03 mm (0.0012
2.017 — 2.020 mm (0.0794 — 0.0795 in)
in) US
#1, #3 0.05 mm (0.0020
2.027 — 2.030 mm (0.0798 — 0.0799 in)
in) US
0.25 mm (0.0098
Crank- 2.127 — 2.130 mm (0.0837 — 0.0839 in)
Crankshaft bearing thick- in) US
shaft
ness STD 2.000 — 2.013 mm (0.0787 — 0.0793 in)
bearing
0.03 mm (0.0012
2.019 — 2.022 mm (0.0795 — 0.0796 in)
in) US
#2, #4, #5 0.05 mm (0.0020
2.029 — 2.032 mm (0.0799 — 0.0800 in)
in) US
0.25 mm (0.0098
2.129 — 2.132 mm (0.0838 — 0.0839 in)
in) US